Apparatus to make pile fabrics in which pile threads are bonded to a base layer

ABSTRACT

A group of plate-like elements, which are hollow between a top and bottom plate are arranged in stacked location, the threads to form the pile fabric being placed adjacent each other between the plate-like elements. A needle-holding web, having needles projecting therefrom is passed intermittently in front of the stacked threads and pressed against the end faces of the threads so that the needles will spear the threads; a knife cuts off the threads, clearing the spearing needles, to transfer the pile threads to the web. The threads between the plates are fed forwardly again by grippers arranged in the hollow between the plate-like elements, the plate-like elements reciprocating back and forth to feed the threads. The web may then be moved to a bonding position at which the cut ends of the pile threads are contacted with a bonding material and, if desired, with a base layer, which is guided over a different path, the then bonded threads being stripped off the needles.

United States Patent [1 1 Messner [451 Feb. 18, 1975 1 1 APPARATUS TOMAKE PILE FABRICS IN WHICH PILE THREADS ARE BONDED TO A BASE LAYER [76]Inventor: Jakob Messner,Unterschauersberg 66, Wels/Thalheim, Austria[22] Filed: Mar. 24, 1972 I21} Appl. No: 237,854

[30} Foreign Application Priority Data Mar. 27, 1971 Germany .1 2114859[52] U.S. Cl 83/278, 83/151,83/151 [51] Int. Cl B26d 7/06 Field ofSearch 83/278, 151, 155, 176, 83/28, 423, 4091, 451, 788, 925 R, 926 R,417, 435.2

[561 References Cited UNITED STATES PATENTS 3,289,510 12/1966 Carter cta1 1. 83/151 3.667662 6/1972 Gilford ct a1. 83/277 X PrimaryE.\amim'rFrank T. Yost Attorney, Agent, or FirmFlynn & Frishauf [57]ABSTRACT A group of plate-like elements, which are hollow between a topand bottom plate are arranged in stacked location, the threads to formthe pile fabric being placed adjacent each other between the plate-likeelements. A needle-holding web, having needles project ing therefrom ispassed intermittently in front of the stacked threads and pressedagainst the end faces of the threads so that the needles will spear thethreads; a knife cuts off the threads, clearing the spearing needles, totransfer the pile threads to the web The threads between the plates arefed forwardly again by grippers arranged in the hollow between theplate-like elements, the plate-like elements reciprocating back andforth to feed the threads. The web may then be moved to a bondingposition at which the cut ends of the pile threads are contacted with abonding material and, if desired, with a base layer, which is guidedover a different path, the then bonded threads being stripped off theneedles.

9 Claims, 7 Drawing Figures PATENTEDFEB 18 I975 SHEET 1 [IF 4PATENTEDFEB 18 ms asssAsQ SHEET u UF 4 1 APPARATUS TO MAKE PILE FABRICSIN WHICH PILE THREADS ARE BONDED TO A BASE LAYER The present inventionrelates to the manufacture of pile fabric, in which individual pilethreads or fibers are joined to a base layer, and bonded to the baselayer; and more particularly to apparatus to make such a pile fabric,and to the pile fabric being formed in an elongated web.

Various apparatus to make textile pile fabrics, chenille fabric and thelike are known, in which cut pile fibers or threads are bonded in abinder, or bonding base substance. These methods are timeconsuming, donot produce material at a rapid rate and provide little opportunity toinsert pile material in accordance with a predetermined pattern.

It has previously been proposed to electrostatically apply carriermaterial with covering layers. When utilized with threads or fibers, thefibers have to be aligned longitudinally, must stand singly, and musthave a certain relationship between their length and their thickness.This method permits only little possibility to provide patterns in pilefabrics.

It is an object of the present invention to provide an apparatus whichis simple and in which selected threads or fibers are applied to a baselayer or to a base material, with low loss of covering pile fibermaterial and permitting application of the pile material in variouspatterns.

SUBJECT MATTER OF THE PRESENT INVENTION Briefly, superimposed layers ofthe threads or the like are fed between stacks of feed plate elementsagainst an intermittently moving, endless web which has needles placedthereon, extending from the web. The web and the fibers are movedagainst each other, so that the projecting needles will spear thefibers. The fibers are then cut to the desired height of the pile. Thepile threads, held on the needles, or between other pile threads whichare held on the needles may then transported towards a binder material,with which the cut ends of the fibers will bond, so that, upontransporting the binder material over a path different from that of theweb, the pile will be stripped off the needles and the pile material, onthe base, will have been produced.

In accordance with an embodiment of the invention, the layers of pilethreads are compressed before introduction of the needles into the endfibers, and cutting of the pile, to obtain the desired pile density.

In accordance with a further feature of the invention, the bonding stepto a base layer can be combined with applying the pile to a basecarrier, such as a carrier web, or backing.

The apparatus is formed of a group of plate-like elements which consistof feed leaves, or the like, between which the threads are located inlayers, each feed leaf having movable grippers located therein, so thatthe threads can be gripped and fed forwardly after each cuttingoperation.

The present invention permits the use of yarn, roving, slivers, cardedribbons, strands, non-woven fabrics, fibrous or filamentary parallelwebs, or the like. Additionally, fibers and threads which heretoforecould not be used in pile fabrics can be processed by the method andapparatus of the present invention, such as spirally interwined fibersor the like.

The invention will be described by way of example with reference to theaccompanying drawings, wherein:

FIG. 1 is a general side view of the apparatus and illustrating themethod;

FIG. 2 is an isometric projection of the feed arrangement for thefibers;

FIG. 3 is an isometric projection, partly broken away, of a feed plate;

FIG. 4 is a partial top view of a feed plate;

FIG. 5 is a longitudinal cross section along line V-V of FIG. 4;

FIG. 6 is a longitudinal cross section along line VI-Vl of FIG. 3; and

FIG. 7 is a greatly enlarged fragmentary side view illustrating thecutting arrangement.

The apparatus has a group of stations. FIG. 1 illustrates, at A, thefeed arrangement in which fibers or threads I, located in verticallystacked layers, are fed forwardly. The feed arrangement A essentially,includes feed plates 2, 3, which are located in a pair of groups B, C,and which are located between the threads 1. The groups B, C areadjacent each other. Each one of the feed plates 2, 3 is formed of a topplate 2a, 3a and a bottom plate 2b, 3b (FIG. 3), between which claws orgrippers 2c, 3c are located. The top and bottom plates are formed withslots 2d, 3d, through which the grippers 2c, 3c may extend. The grippersare in the form of claws, or with reversely bent hooks, such asfishhooks. The grippers 2c, 3c are located on a tongue 2e, 3e which isslidable in order to feed the threads l.

The tongues 22, 3e are moved, for example, by means of a compressedfluid cylinder 4, 5, having piston rods located in holders 6, 7. Theholders 6, 7 are located in carriers 8, 9 which, in turn, can be movedby means of compressed fluid cylinders 10, II to move the entire groupsB, C of the plate-like elements in feed direction, or in directionopposite thereto, the grippers being pushed outwardly to grip thethreads when the carriers 8, 9 are moved in feed direction, and to holdthe threads, and the grippers being retracted upon reverse movement ofthe carriers 8, 9.

The slots 3d formed in the upper and lower plates 3a, 3b (FIG. 6) are soarranged that the grippers 30 can extend therethrough and thus passbeyond the upper and lower plates 3a, 3b. Upon movement of the tongue 3ein opposite direction, the grippers 3c retract within the two platesfrom the slits 3d and are completely retained between the top and bottomplates 30, 3b of the platelike element 3. The movement is similar to theextension and retraction of claws of a cat.

An endless web 12 which has needles placed thereon extending from theweb is moved transverse to the end face direction of the threads 1. Thefeed assembly A is associated with a frame 13, movable in feeddirection, which retains the threads 1 which extend beyond the ends ofthe plate-like elements 3. The lower part of the frame 13 has a counterelement 14 (FIG. 7) connected thereto. A horizontally movable plate 15,in the nature of a back-up plate is movable by means of a compressedfluid cylinder 15' in horizontal direction, to press the needles againstthe end faces of the threads, and spear the threads thereon. A cutter C(FIG. 7) cuts the threads into pile elements. In a preferred form, it isa band, or thin blade knife which is movable in vertical direction. Whenthe cutter C is moved against the stack of fibers, the fibers are cut,as best seen in FIG. 7.

The cut fibers, speared on the needles of the needleholding web, orretained between other fibers which are so speared, are carried by theweb 12 over a roller 28, to be transferred to a shearing station D,where the lengths of the fibers are equalized. A roller 16, which may beformed with projections equalizes, or forms a pattern in the threadsspeared on the needles of web 12. The roller 16, likewise, can be movedback and forth, that is, away from the web by means of a pressure fluidactuated cylinder-piston arrangement 16'.

The web 12, with the fibers thereon, equalized or patterned at station Dis then introduced between rollers 17, 18. Additional to the web, a baseor back-up carrier 19 is introduced between the rollers 17, 18 on which,prior to such introduction, a bonding, or adhesive layer has beenapplied by a spreading knife 19'. The web 12, with the fibers retainedthereon, is carried in contact with the Karrier web 19, and its adhesiveand bonding layer over a heating drum 20, then through a cooling path 21and thereafter over a removal drum 22. The finished pile fabric isrolled on a drum 23; the needle carrying web 12, now free from pilefibers, is returned to the region of the feed assembly A.

Rather than utilizing a carrier 19, a re-usable backing can be used, ifthe final pile product is to be made without a backing fabric.

OPERATION The starting position of the various elements is shown inFIG. 1. The faces of the stack of fibers are spaced from the needlecarrying web 12 by a predetermined distance. By means of the feedarrangement A, the faces of the stack of fibers are moved towards theneedle carrying web 12. The grippers 2c, 30 are extended by placingpressure fluid, such as compressed air, or oil, into cylinders 4,5. Thegrippers will now pass through the slots 2d, 3d and extend beyond theupper and lower plates of the plate-like elements 2, 3. The grippers 2c,30 will penetrate into the fibers from both sides of the plate-likeelements 2, 3, so that the fibers are gripped both from the top and thebottom. The pressure cylinders 10, 11 then will have pressure appliedthereto and the groups B, C of plate-like elements are moved towards theright, that is, towards web 12 with the needles thereon.

The grippers 20, by suitable operation of the tongues 2e, are thenretracted, so that the grippers 2c are removed from engagement with thethreads 1, the threads 1, however, being held in position by thegrippers 30. The group B of plates is then moved towards the left, theplate-like elements 2 passing over the corresponding layers of thefibers. When in final position, the grippers 2c are again projected andpenetrate the fibers 1, to hold the fibers securely, in order to permitthe next cycle during which the grippers 3c are'retracted, to separatefrom fibers 1 and permit movement of the group C of the plates 3 towardsthe left (FIG. 1). In the final position, the grippers 3c are againprojected such that, in this position, both grippers 2c, 3c of bothgroups again again grip the fibers and are ready for the next cycle.

The stationary web 12 is then pressed by means of plate into the endfaces of the stack of fibers. A top rail 27 connected to frame 13 holdsthe edge of the fibers in straight line position and permits spearingby, or insertion of the needles of the web 12.

The cutter C then cuts the threads 1, by movement of the cutter bladedownwardly. The web 12 can, at this time already, be started to move.The cut is carried out, as shown in FIG. 7, the distance of cut from thebase of the web 12, of course, being sufficient so that the knife edgewill clear the tips of the needles on the needle carrying web 12. Asection of the needle carrying web 12 now has the threads, or fibersspeared or located thereon. The portion of web 12 changes directionadjacent the cutting by being guided around a sheave 28. The entirecutting arrangement C, including the back-up plate 15 and sheave 28move, in a vertical direction, relatively to the feed apparatus A; ofcourse, the feed apparatus A could also be moved vertically and thecutter be held stationary. The band-knife of the cutter C isschematically indicated in FIG. 1, and in detail in FIG. 7.

The web is then guided over a compensating loop to the equalizingstation D. The end faces of the threads can be held in pre-compressedcondition, to permit control of the tightness of the pile, between thetop rail 27 and the bottom rail 14.

After the cutting operation, the cutter C and plate 15 are moved back tothe initial position, shown in FIG. 1, and feed of a next section offibers 1 can commence.

The back-up carrier 19 is introduced between rollers 17, 18 and ispressed against the web 12, filled with fibers. The portion of the web12 which is filled with fibers, together with the carrier 19, is thenconducted over the heating drum 20 and, after being guided thereabout,to a further roller 24 and to the cooling path 21. The group of rollersbetween rollers 12, 18 and heating drum 20 is utilized as a compressionstation to securely compress or embed the pile threads into the adhesiveof the carrier web 19. Heating and subsequent cooling bonds the fibersin a heat-setting adhesive applied to the carrier 19. The bondingstrength between the carrier 19 and the fibers is greater than theholding strength of the needles on the needle web 12, so that, when theneedle web 12 and the carrier 19 are moved over different paths, bylooping the carrier about a roller 22, the fibers are removed from theneedle web 12 and can be rolled on a take-up roller 23. The now freedneedle carrying web 12 is again returned to the feed apparatus A whereit is stopped, and moved at that section only upon start of the cuttingoperation. The needle band 12 moves conjointly with the cutter C and theplate 15, after the cutting operation has been terminated, and plate 15has been retracted to the right (FIG. 1).

A brush 25 may be provided to clean the needle band 12 which,additionally, can be cleaned by compressed air blast from a pipe 26.

The needles of the needle bed 12 suitably are somewhat shorter than thelength of the pile, at least by the depth of the backing. It is alsopossible, however, to make the needles of the needle bed 12 as long, orlonger than the cut pile threads, if the extent of movement of theback-up plate 15 is suitably controlled so that interference between theknife of cutting assembly C and the needles isprevented.

The needles on the needle bed need not all have the same length; longerneedles can be very pointed, and shorter needles can be provided whichare somewhat blunt. The degree of conical taper, the thickness, and thestrength of the needles of the needle carrying web 12 are preferably soselected that the pile threads which are speared, and cut, are securelyheld in projecting direction. The longer needles, then, only have topenetrate the adhesive layer and the carrier. It is possible to insertinto the needle web 12, with long needles, a filler or liner, which iselastic, and which is of such thickness that the remaining free lengthis shorter by the distance of the adhesive bed with respect to thelength of piles to be cut.

That portion of the band knife which faces the roller 28 is hollowground, the radius of hollowness of the grinding being approximatelyequal to the thickness of the web 12 and the needles, plus the radius ofroller 28.

The cut pile fibers or threads secured to the web 12 are preferablyprofiled, and equalized before they are bonded to the adhesivesubstrate. It is also of advantage to loop the needle band or web 12with the pile material thereon about a roller in which the needles facethe direction of the roller in order to obtain suitable pressure on thepile by the tension of the web 12.

In accordance with a feature of the invention, the pile material can befed to the needle holding web 12 with more fibers than there areneedles, the fiber being held between the needles. It is also possibleto cut the pile much longer than necessary and, after cutting and movingthe web 12 with the needles and the elongated piles thereon away fromthe feed apparatus A, to guide the pile against a second needle holdingweb, similar to web 12 in such a manner that the needles of the secondweb will engage the pile held on the first web, and then to cut the pilebetween the needles.

The bonding and equalizing device may operate continuously, whereas thefeed and cutter operate intermittently. To provide for continuousoperation of the web where it is continuously operating, suitable slackloops. and the like, if necessary guided by rollers such as roller 50and movable in a longitudinal direction can be used. The upper positionof roller 50 is indicated in FIG. 1 at 50', and the path of the web 12is indicated in dashed lines when tight, the movement of roller 50between the full line position and the dashed line position at 50'providing for a slack loop.

Various changes and modifications may be made within the inventiveconcept.

I claim:

1. Apparatus to make pile fabric in which individual pile threads orfibers are joined to a base layer comprisa needle holding web (12)having projecting needles transverse to the web;

means (15) guiding the web to the end faces of the threads with theneedles projecting towards the end faces of the threads to spear atleast some of the threads on the projecting needles; cutting means (C)severing the threads at a position beyond the insertion depth of theneedles;

and thread feed means (A) comprising a plurality of spaced, stacked,plate-like elements (2,3) adapted to hold the thread therebetweenessentially in parallel alignment and to have the end faces of thethreads exposed at the ends of the plates;

gripping means (20, 3c) located on said plate-like elements and movablebetween a projecting position in which the threads between the platesare engaged, and a retracted position in which the gripping means areout of contact with the threads;

and means cyclically moving the plate-like elements transverse to theweb (12) and moving the gripping means to grip the thread when theplate-like elements are moved towards the web to feed a pile of threads,and to retract the gripping means when the plate-like elements areretracted in advance of the next feeding movement. 2. Apparatusaccording to claim 1, wherein the platelike elements are arranged in twosimilar groups alternately stacked above each other;

and carrier elements are provided supporting each group of plate-likeelements, said carrier elements moving the plates, alternately, and thegripper means cyclically, to be alternately projecting so that thegripper means of one group will hold the threads while the gripper meansof the other group is moving, and vice versa. 3. Apparatus according toclaim 1, wherein each plate-like element comprises a top plate (2a, 3a);a bottom plate (2b, 3b); slots (2d, 3d) formed in said plates, thegripper means (20, 3c) being extendable through said slot;

and a control tongue (2e, 3e) extending between the plates and connectedto the respective gripper means to control movement thereof.

4. Apparatus according to claim 3, further comprising fluid operablemeans located externally of the plates and connected to said tongues tomove the tongues and hence the gripper means.

5. Apparatus according to claim 1, comprising a frame (13) which ismovable in a direction of movement of said moving means and located tosupport the ends of the threads extending beyond the plate-likeelements.

6. Apparatus according to claim 5, wherein said frame comprises a rail(27) effecting a compressive force against the top layer of the fibersto compress the fibers during insertion of the needles.

7. Apparatus according to claim 6, wherein the frame further comprises acounter rail (14) to counter the compressive force of said first rail(27).

8. Apparatus according to claim 1, wherein the guide means comprises aplate (15) movably transverse to the threads and located behind theneedle holding web, the guide plate being moved against the web to pressthe needles of the web into the end faces of the threads.

9. Apparatus according to claim 1, wherein the cutting means comprises aband knife, and said band knife and stack of threads are relativelymovable transverse to the longitudinal extent of the threads.

1. Apparatus to make pile fabric in which individual pile threads orfibers are joined to a base layer comprising a needle holding web (12)having projecting needles transverse to the web; means (15) guiding theweb to the end faces of the threads with the needles projecting towardsthe end faces of the threads to spear at least some of the threads onthe projecting needles; cutting means (C) severing the threads at aposition beyond the insertion depth of the needles; and thread feedmeans (A) comprising a plurality of spaced, stacked, plate-like elements(2,3) adapted to hold the thread therebetween essentially in parallelalignment and to have the end faces of the threads exposed at the endsof the plates; gripping means (2c, 3c) located on said plate-likeelements and movable between a projecting position in which the threadsbetween the plates are engaged, and a retracted position in which thegripping means are out of contact with the threads; and means cyclicallymoving the plate-like elements transverse to the web (12) and moving thegripping means to grip the thread when the plate-like elements are movedtowards the web to feed a pile of threads, and to retract the grippingmeans when the plate-like elements are retracted in advance of the nextfeeding
 2. Apparatus according to claim 1, wherein the plate-likeelements are arranged in two similar groups alternately stacked aboveeach other; and carrier elements are provided supporting each group ofplate-like elements, said carrier elements moving the plates,alternately, and the gripper means cyclically, to be alternatelyprojecting so that the gripper means of one group will hold the threadswhile the gripper means of the other group is moving, and vice versa. 3.Apparatus according to claim 1, wherein each plate-like elementcomprises a top plate (2a, 3a); a bottom plate (2b, 3b); slots (2d, 3d)formed in said plates, the gripper means (2c, 3c) being extendablethrough said slot; and a control tongue (2e, 3e) extending between theplates and connected to the respective gripper means to control movementthereof.
 4. Apparatus according to claim 3, further comprising fluidoperable means located externally of the plates and connected to saidtongues to Move the tongues and hence the gripper means.
 5. Apparatusaccording to claim 1, comprising a frame (13) which is movable in adirection of movement of said moving means and located to support theends of the threads extending beyond the plate-like elements. 6.Apparatus according to claim 5, wherein said frame comprises a rail (27)effecting a compressive force against the top layer of the fibers tocompress the fibers during insertion of the needles.
 7. Apparatusaccording to claim 6, wherein the frame further comprises a counter rail(14) to counter the compressive force of said first rail (27). 8.Apparatus according to claim 1, wherein the guide means comprises aplate (15) movably transverse to the threads and located behind theneedle holding web, the guide plate being moved against the web to pressthe needles of the web into the end faces of the threads.
 9. Apparatusaccording to claim 1, wherein the cutting means comprises a band knife,and said band knife and stack of threads are relatively movabletransverse to the longitudinal extent of the threads.